Rajan Wilcox
Setting up a race car fuel system is a complex task that requires careful consideration of various components such as fuel pumps, lines, filters, and regulators. The choice of these components depends on factors like engine size, power requirements, fuel type, and racing regulations. One crucial aspect is selecting a suitable fuel pump that can deliver the required fuel volume and pressure for the engine's horsepower. This involves calculating the fuel consumption based on factors like brake-specific fuel consumption and engine weight. Additionally, the fuel lines must be securely mounted and protected from debris, and the use of electric or mechanical pumps depends on the racing class and safety considerations. The fuel system must also be designed for quick and safe refueling during pit stops, and the fuel type and storage containers are important to ensure fuel stability and performance. Overall, optimizing the fuel system's performance requires proper sizing, maintenance, and compatibility between components.
Characteristics and Values of a Race Car Fuel System
| Characteristics | Values |
|---|---|
| Fuel Type | Gasoline, E85, Race Gas, Alcohol |
| Fuel Containers | Metal, Opaque Plastic, Black Plastic Fuel Cans |
| Fuel Lines | OEM Fuel Lines, Steel or Flexible Steel Lines, Rubber or Neoprene Hoses |
| Fuel Pumps | Mechanical, Electric, High-Pressure DI Pumps |
| Fuel Filters | 5-40 Micron Filter, Stainless Steel Filters |
| Fuel Pressure | Varies Depending on Engine Type and Fuel Injection Method |
| Fuel Volume | Sufficient Volume to Support Engine Horsepower |
| Fuel System Maintenance | Regular Cleaning and Replacement of Filters |
| Fuel Refilling | Specialized Equipment, Quick and Safe Process |
| Fuel Hose | MIL SPEC Hard Anodizing for Longer Life |
| Fuel Coolers | Used in Endurance Racers to Prevent Performance Loss |
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What You'll Learn
Fuel pumps
The fuel pump plays a critical role in the performance of a race car. Its function is to pump fuel from the tank (or swirl pot) to the injectors. Modern fuel pumps are typically electric, although some race cars use mechanical pumps.
When selecting a fuel pump, it is important to consider the engine size, power requirements, fuel type, and any restrictions on the type of pump (electric or mechanical). The pump should be able to deliver sufficient fuel volume to support the engine's horsepower production. As a general rule of thumb, one gallon of gasoline per hour can support approximately 10 horsepower for a naturally aspirated engine. However, it is important to note that different fuel types, such as E85 or methanol, will require a higher volume of fuel.
It is also crucial to consider the fuel lines and fittings. The lines should be securely mounted to the chassis and protected from debris or any errant broken parts on the track. Stainless steel filters and elements are often used with methanol to ensure compatibility. Additionally, the use of a fuel swirl pot or a fuel cell with baffles can help prevent fuel surge during cornering.
To optimize fuel system performance, proper sizing and maintenance are essential. Oversizing injectors by more than 25% can negatively impact idle quality and throttle response. It is recommended to use a 100- to 200-micron filter before the fuel pump and a smaller micron filter before the injectors or carburetor to protect the system and ensure smooth fuel delivery.
Finally, it is worth noting that fuel pumps can be mounted inside or outside the fuel tank. While an internal pump benefits from the tank's design to keep the fuel at the inlet, an external pump offers the advantage of quick replacement. When mounting the pump externally, it is important to keep it as close and low as possible to ensure proper fuel flow and to insulate the pump and fuel lines to maintain optimal fuel temperature.
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Fuel lines
The type of fuel lines used can vary depending on the application. Original Equipment Manufacturer (OEM) fuel lines are typically made of a combination of hard steel lines and flexible steel or rubber hoses. While OEM fuel lines are durable, they may not be suitable for race cars due to the elevated level of maintenance and the potential for wear and tear on the fittings and threaded joints.
When selecting fuel lines for a race car, it is important to choose those made from high-quality materials that can withstand the extreme conditions of racing. Some options include stainless steel, braided lines, or hoses with MIL SPEC hard anodizing, which offers better durability and corrosion resistance.
The sizing of the fuel lines is also critical. The lines must be large enough to accommodate the required fuel flow rate, which will depend on the engine's horsepower and fuel consumption rate. Insulating the fuel lines, especially those running through hot areas, is important to maintain optimal fuel temperature and prevent fuel breakdown.
Additionally, proper routing of the fuel lines is essential for both performance and safety. The lines should be securely mounted to the chassis and protected from debris or errant parts that could cause damage. It is crucial to ensure that the fuel lines do not interfere with any suspension parts or other components that could impact or rub against them. Cochran, an expert in the field, advises, "When you are running your lines, you need to let the hose end route the hose, not just use straight hose ends and bend the hose."
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Fuel filters
When choosing a fuel filter, it is important to consider the fuel type and the engine's power requirements. For example, when using methanol, it is recommended to use stainless steel filters with stainless steel elements to ensure compatibility and prevent corrosion. The filter's surface area must also be considered, especially when dealing with high-flow fuel pumps. A larger surface area is necessary to accommodate the increased fuel flow while maintaining the appropriate micron rating to effectively filter out contaminants.
The placement of the fuel filter is another critical factor. Some experts recommend installing a filter before the fuel pump to protect it from contaminants, typically with a micron rating between 100 and 200. Additionally, a second filter is often placed before the injectors or carburetor, with a smaller micron rating ranging from 5 to 40, depending on the specific application.
It is important to regularly maintain and replace fuel filters as they can become clogged over time, impacting the engine's performance and potentially leading to more serious issues. The frequency of replacement will depend on various factors, including the type of fuel used and the engine's power output.
Finally, it is worth noting that while most standard filters can handle moderate power increases, specialized "race" filters are available for high-power engines and exotic fuels. These filters are designed to meet the unique demands of racing environments and help ensure reliable performance.
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Fuel storage
The choice between using the original equipment manufacturer (OEM) fuel lines or upgrading them is also essential. OEM fuel lines are durable but may not be suitable for the elevated maintenance and performance demands of race cars. If using OEM fuel lines, they typically consist of a combination of hard steel lines and flexible steel or rubber hoses. When opting for aftermarket fuel lines, racers should consider the type of fuel and the engine's power to select the appropriate material and size. Braided lines, for example, can be used with inlet lines, and the containers should be metal or opaque plastic, with black plastic being the preferred choice for transferring gasoline.
The fuel pump plays a vital role in delivering fuel from the tank to the injectors, and it is important to select the right type and size for your engine. Modern fuel pumps are typically electric, but some race cars still use mechanical pumps. The pump should be matched to the engine's horsepower and specific application, with considerations for the fuel type and any restrictions on electric or mechanical pumps imposed by the racing class. Additionally, the pump should be mounted as close and low to the tank as possible for proper fuel flow, and it should be insulated, along with the fuel lines, to maintain optimal fuel temperature.
The fuel filter is another critical component in fuel storage as it removes foreign objects that could block the injectors or damage the engine. It is important to select a filter compatible with the fuel type and the fuel flow rate. Stainless steel filters with stainless elements are often used with methanol fuel. The filter element's surface area should be proportional to the fuel flow rate to prevent blockage and ensure effective filtration. Regular maintenance and replacement of the fuel filter are necessary to maintain optimal performance and prevent engine issues.
Lastly, it is important to consider the fuel type and its specific requirements. For example, alcohol-based fuels like E85 and methanol can leave residue and create a tar-like substance if left in the system for extended periods. This can lead to stuck injectors and engine issues if not addressed. Therefore, regular maintenance and the use of appropriate filters are crucial when using alcohol-based fuels.
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Refuelling
The refuelling process typically involves a fueler, who fits a specially designed nozzle into the port in the side of the race car, and a fuel hose assistant, or "deadman", who operates a spring-loaded lever on the fuel tank to control the flow of fuel and can stop the release of fuel if any problems are detected. The fueler and assistant must work together to ensure the fuel hose remains level to facilitate the quick release of fuel.
The specific refuelling procedures and equipment can vary depending on the racing organisation and regulations. For example, as of the 2010 racing season, refuelling is no longer allowed during Formula 1 races, while Indycar and NASCAR still allow refuelling during their competitive races. NASCAR utilises a "dump can" fuel can type, which can release fuel into the vehicle within eight seconds, with each can holding 11 gallons, requiring two cans to refuel a car. Indycar, on the other hand, prioritises safety by refuelling the vehicle only after all tires have been replaced, and the process takes a maximum of 2.5 seconds.
It is crucial to consider the type of fuel and its specific requirements when designing a refuelling strategy. For instance, prolonged exposure to sunlight can cause some race fuels to break down, and certain fuels, like alcohol-based ones, can leave a residue if left in the system for extended periods, impacting performance. Additionally, the container type and colour are important considerations, with black plastic containers being ideal for transferring gasoline, while alcohol-based fuels can be stored in translucent or light-coloured containers.
Furthermore, the fuel pump plays a critical role in ensuring efficient refuelling and engine performance. Modern fuel pumps are typically electric, but some race cars use mechanical pumps, and it is essential to select a pump suitable for the horsepower level and specific application. Upgraded pumps come in various shapes and sizes, and it is important to ensure the pump matches the engine's requirements to prevent issues like fuel surge.
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Frequently asked questions
The key components of a race car fuel system include the fuel tank or cell, fuel pump, fuel filter, fuel lines, rails, regulator, and injectors or carburetor.
When setting up a race car fuel system, it is important to consider the engine size, power requirements, fuel type, and any restrictions on the type of fuel pump (electric or mechanical). The fuel lines should be securely mounted to the chassis and protected from debris or errant parts on the track. It is also crucial to ensure proper sizing and maintenance of the fuel system components.
Refueling a race car during a pit stop can be tricky and dangerous. It requires specialized equipment to make the process quick, safe, and efficient. The fueler fits a specially designed nozzle into the port on the side of the race car, while the fuel hose assistant operates a spring-loaded lever on the fuel tank to control the fuel flow. The refueling process should be completed within a short time frame, typically 15 seconds or less.
